Art of curing and packaging building material



Jan.. 2, 1940. N. P. HARSHBERGER ART 0F CURING AND PACKAGING BUILDINGMATERIAL Original Filed Nov. 22, 1952 2 sheetssheet INVENTOR ATTORNEYART 0F CURING AND PACKAGING BUILDING MATERIAL original Filed Nov. 22,1952 2 Sheets-Sheet 2 ATTO RNEY Patented Jan. 2, 1940 ART OF CURING ANDPACKAGING BUILDING MATERIAL Norman P. Harshberger. Scarsdale, N. Y.,assignor to Bakelite Building Products Co., Inc., New York, N. Y., acorporation of Delaware Original application November 22, 1932, SerialNo.

Divided and this application January 17, 1936, Serial No. 59,503

6 Claims.

This invention relates in general to improvements in the art ofstacking, packaging and curing building materials and is a division ofmy copending application Ser. No. 643,891, led Nov.

More particularly, this invention has reference to the stacking,packaging, and'curing of shingles consisting of a treated fibrous basecoated with a layer of any viscous materials, contemplating bituminousor resinous types, and a layer of hydraulic cement wherein the hydrauliccement is caused to adhere to the coated base preferably by a suitablebonding medium.

Rigid shingles, containing cement as a principal ingredient, must bepermitted to cure for a period of approximately six weeks andheretofore, during this slow curing process the moisture has been lostbefore the cement has fully set, thus permitting lime action to takeIplace and causing the formation of an objectionable surface layer ofdust. In rigid shingles of the type heretofore made, in order to retainsufficient moisture to produce proper curing, an excessively thicksection would have to be employed. Aside from the above-mentioneddifficulties the curing of cementitious shingles which are not mountedon a fibrous base presents many other difficulties.

With the type of rigid shingle contemplated by the present invention,however, wherein there is y I therefore during the curing process andduring the setting of the cement, curling is likely to take place ifordinary curing methods are employed for the curing of fibrous basedshingles.

It is one of the objects of the present invention to provide a methodparticularly adapted for the making and curing of cementitious shingleshaving a fibrous base as a part thereof, in which the fibrous basesupports the cementitious layer in handling and in which the curing isso accomplished as to prevent the possibility ofthe individual shinglescurling and to prevent elorescence and consequent disfiguration anddiscoloration of the surfaces.

A further object of the invention is to provide a method of curingshingles wherein the moisture which is inherent in the hydraulic cementis retained for a relatively long period to prevent the formation of anobjectionable surface layer of dust and to prevent lime action.

A still further object of the invention is to pro- This is because ofthe v vide a method of curing shingles which includes the promptstacking of the cut units and the curing of the shingles in stackedrelation, i. e., with the sides of the units facing each other, thusenabling the manufacturer to cornpa'ctlyA store the u shingles duringthe curing process.

A more specific object of the invention is to provide a method as abovedescribed wherein novel separating means are employed between theindividual shinglesv in the stack to prevent adherence of the shinglesto one another and wherein said means may include independent separatingmedia and/or separating ingredients in the cement mixture and/orseparating ingredients in the material forming the base of the shinglesand/or a separating layer adhering to the base of the shingles and/orthe formation of the shingle surface or surfaces in such a manner as toprevent adhesion with adjacent shingles.

With the above and other objects in view', the invention consists of theimproved art of making and curing shingles and all its'parts andcombinations as set forth in the claims, and all equivalents thereof.

In the accompanying drawings in which the.

same reference numerals designate the same parts in all of the views:

Fig. 1 isa plan View of an individual shingle;

Fig. 2 is an exaggerated sectional view taken on line 2 2 of Fig. 1;

Fig. 3 is a similar section showing a modified form of construction; i

Fig. 4 is a cross-sectional View of a stack of shingles illustrating themethod of stacking shingles of the type illustrated in Figs. 2 and 3;

Fig. 5 is a perspective view of a stack of shingles showing a modifiedmethod of separation;

Fig. 6 is a. sectional view similar to Figs. 2 and 3,

illustrating a modified form of shingle;

Fig. 7 is a cross-sectional view showing the method of stacking shinglesof the type illus--- trated in Fig. 6; 4

Fig. 8 is a sectional view similar to Fig. 2 showing still another formyof shingle which may be utilized in connection with the .improved curingmethod;

Fig. 9 is a cross-section of a partially double surfaced shingle;

Fig. 10 is a cross-section showing the method of stacking the shinglesof Fig. 9;

Fig. l1 is a cross-sectional view illustrating a shingle which is onlypartially surfaced on one side;

. Fig. 12 is Aa cross-sectional view showing the method of stacking theshingles of Fig. 11;

Fig. 13 is a cross-sectional view showing a modified method of stackingthe shingle of Fig. 6;

Fig.v 14 is a cross-sectional view illustrating a modified method ofstacking the shingles of Fig. 2;

Fig. 15 is a similar View showing still another method of stacking theshingles of Fig. 2;

Figs. 16, 17 and 19 are cross-sectional views showing other types ofshingles which may be cured by the improved method; and

Fig. 18 is a cross-sectional view showing the method of stacking curvedelements.

Referring more particularly to the drawings, the shingle illustrated in'Figs. 1 and 2 consists of a fibrous base I0 which vmay be paper,felt orthe like which has been saturated with a suitable viscous material suchas asphalt, and

,coated with a similar material as at H. A surface layer I2 of hydrauliccement is formed over the layer I I and this cement may be an ordinaryPortland cement but is preferably a high early strength (acceleratedhardening) Portland, for instance, commercial Incor, or a quick settingPortland, but better still, preference is given to a high aluminacement, for instance, commercial Lumnite, and which also may be quicksetting,

to obtain certain beneficial characteristics'v in the carrying out ofthe invention. In order to obtain a suitable bond between the asphalticcoating II and the cement layer I2, some type of bonding medium ispreferably employed and in Fig. 2 the bonding medium consists of mineralparticles I3, such as for example, slate, embedded in and projectingabove the asphalt coating II. These particlesv are gripped by the cementI2. when it sets. As illustrated in a modification, Fig. 3, this bondingmedium may be a fibrous material such as mineral wool, vegetable fibersor animal hair as at I3.

In the manufacture of the product it is preferred to form the asphaltcoated base as a web, and to add mineral particles or other bondingmedium to the surface of said web. The web is then preferably cut toform individual shingle units, and vthese units are then coated with alayer of hydraulic cement. It is, however, possible to coat the entireweb with cement prior to the cutting. With either method, however, theindividual shingles are formed before the cement has set, and' theshingle is then com.

pleted except for the curing process which forms the subject matter ofthe present invention.

Ordinarily, the curing process is relatively slow, and the moisturewhich is inherent in the hydraulic cement evaporates before the cementhas had an opportunity to properly hydrate and set, thus causing theformation of an objectionable dust on the surface of the article, andwith certain hydraulic cements permitting lime action to take place. Oneof the important features. of the presentv invention relates to theprevention of the rapid loss of moisture from the cement. i

The above is accomplished by immediately stacking, i. e. arrangingwiththeii sides facing retained. for a relatively long period and untilafter the setting of the cement has taken place. It has been found thatwhen the individual shingles are separated, after the curing has beensufficiently completed, that various surface formations ranging fromsmooth effects to irregular or mottled eects, in which no two elementshave exactly similarformations, may be obtained. The degree of theeffects so produced can be controlled by proper surface preparation andby regulation of the stacking yand curing operations.

In order to obtain the above advantages of stacking, however, it isnecessary to cope with the problem of preventing the shingles frombecomingl bonded to one another in the stack.

The present method therefore includes as an important feature. the useof a suitable separat'- ing means to prevent the cement coating of oneshingle from becoming bonded to the shingle above. One form ofseparating medium is provided by mixing with the hydraulic cement,before its application to the shingles, ingredients which come to thesurface of the cement and form a separating lm thereon. For this purposeit is preferred to mix with the cement, fractions of one to tenpercentof such ingredients, and these ingredients may be material suchas synthetic resin, asphalt, wax, or oilsuch as linseedv'or tung oil.These materials will, as before mentioned, appear on the surface of thecement when it sets, and will form the desired separating lm.

In addition to the separating means above defined or `as a substitutetherefor, the back of each shingle mayv be coated with a suitableseparating layer or have combined with its composition a suitableseparating substance. The material comprising this layer or separatingsubstance may be any that will not combine withv the cement and whichwill prevent union with the cement of the next contacting shingle. For.

by the separator, and the latter will shrink and form wrinkles. Due tothe weight of the stack on the separator, these wrinkles will be pressedinto the cement, and as the latter sets, the surface will be formed withwrinkles therein simulating the grain of wood. After the curing processhas taken place, the separating pieces I4 may be readily removed becauseof the non-adherence of the cement to the separator itself.

An additional method of preventing adherence of the-individual shinglesto one another while stacked for curing is illustrated in Figs. 6 and 7.When this method is employed the crushedmineral or pebbles such as thatused at I3 in Fig. 2, is of a coarser nature so that it projects abovethe cement layer I2, as at I5. When shingles of this type are stackedfor curing, the projecting mineral particles I5 will tend to slightlyelevate the shingle above to prevent contact with the setting cement, asindicated in Figs. 7 and 13.

In Fig. 8 a shingle is illustrated which is identical to thatillustrated in Fig. 2 exceptthat the asphalt coating II, mineral I3; andcement coating I2 is applied on both sides of the fabric 75 base l0 toprovide a'reversible shingle. Fig. 9

illustrates a partially coated shingle wherein only the portion to beexposed to the weather has been surfaced. 'I'he method of stacking theseshingles is shown in Fig. 1 0, and a suitable separating medium asbefore described may be employed.

The type of shingle illustrated in Fig. 11 is surfaced in the mannerdescribed in connection with Fig. 2 exceptv that the'surfacing is onlyon the portion of the shingle which is to beexposed in assembly. Thistype of shingle may be stacked in the manner indicated in Fig. 12, asuitable separating means being employed.

As it is sometimes more practical in packaging to have thetop and bottomsides of an article lying in flat planes it may be arranged in themanufacturing process to take a shingle as shown in Fig. 11 and apply tothat portion comprising the unsurfaced part, a layer of bituminousmaterial I6 as shown in Fig. 16.

Fig. 17 shows an element surfaced and coated on both sides to obtainthe' same result as in Fig. 16.

While nearly all of the figures illustrated show elements of a flattype, this in no way should be construed to mean that shaped elementsare not contemplated by this invention. One of the shaped elements ofthis type is illustrated in stack formation in Fig. 18.

The shingle illustrated in Fig. 19 is also designed to obtain the resultof Fig. 16, but in this form the coating of asphalt Il and the grit I3cover the entire surface. The cement., layer I2 is used only on theportion to be exposed andthe remainder of the shingle is leveled with alayer of bituminous material I6.

As an additional step in any of the above methods the cut and stackedelements may be subjected to pressure for the purpose of extruding suchsurplus hydraulic cement as may be desired and suitable means may bethen employed for removing the surplus cement from the edges of thestack. This may be done by any ordinary scraping step. The scraping stepmay be also applied to the surface of individual elements to removesurplus material, if so desired. Also where it is desired to have thecoating project beyond or over the edges of .the stacked shingles andyet prevent adhesion of the adjacent shingles in the stack, the surpluscement may be received by separators having portions projecting beyondthe shingle edges. This type of separator is indicated at I4 lin Fig. 14and may be employed in any of the stack arrangements disclosed. Wherepebbles or the like are used as separating means, as in Fig;l 7, theedges of the elements may be protected by any suitable means to preventthe evaporation of moisture.

A further verymaterial use of this novel curing method is in overcomingloss of color where the cement is mixed with coloring pigments, and thecombination of cement and coloring pigments is therefore contemplated bythis in vention. l

An additional advantage gained from the use of the viscous materialsdescribed heretofore in combination with the cement is that ofpreventing lime action from taking place, thus preventing eiilorescenceand any other disguration or discoloration to the .surface by precludingthe evaporation of moisture.

From the above it may be seen that a very desirable method of making andcuring shingles has been described wherein a brous based cement shingleis cured in stacked formation to prevent curling of the shingles and toprevent loss of moisture and wherein means are utilized as a step in themethod of preventing the shingles from becoming bonded to one anotherduring the curing process.

I claim:

1. The method comprising applying a surface layer of plastic cement upona resilient base material capable of supporting said layer, forming acompact grouping consisting of units of said cement surfaced basematerial and with the sidesof the units facing each other, forming saidgroup while the cement is still plastic, covering eachcement surfacingof the grouped units with a fibrous separator which will not bond to thecement and of greater dimension than said units to'substantially preventbonding between adjacent units, arranging said separators as to projectbeyond the edges of said units, edge coating the units as thus arrangedwith plastic cement and permitting the cement to harden.

2. The method comprising applying a surface llayer .of plastic weatherresistant material upon a fibrous base of sufficient shape retainingproperty to support by itself said plastic layer, forming a compactgrouping consisting of units of said surfaced base material and with thesides of the units facing each other, forming said group while thesurfacing layer is still plastic, covering each plastic surfacing of thegroup units With a separator which will not bondto the surfacing layerand of greater dimension than said units to substantially preventbonding between adjacent units and placing said separators as to projectbeyond the edges of said units, edge coating the base of said units byapplying pressure tothe surfacing units so arranged, and to cause flowof the plastic surfacing material over the edgesv thereof, and curingthe units as thus arranged. v

3. The method of making and curing cementitious shingles comprisingsecuring a surface layer of plastic hydraulic cement to fibrous basematerial of suicient rigidity to support by itself said cement layer,forming a compact grouping consisting of a plurality of units of saidcement surfaced base material and flexible membranes that will not bondto hydraulic cement, forming said group while the cement is stillplastic and forming said group with the Vsides of the units facing eachother and with said flexible membranes covering each cement surfacing ofthe group to substantially prevent bond of the hydraulic cement layer ofone unit with a side of an adjoining unit in curing, and curing theunits as thus arranged, said units being adapted for packaging withoutregrouping the individual layers.

4. The method of making and curing cemenbase material of sufficientrigidity to support by itself a plastic hydraulic cement layer, dividingand surfacing said material with a layer of hydraulic lcement to formcement surfaced units, forming a compact grouping consisting of aplurality of said units and flexible membranes that will not bond tohydraulic cement, forming said group while the cement is still plasticand forming said group with the sides of the units facing each other andwith said flexible membranes covering the plastic cement layers tosubstantially prevent bonding of the hydraulic cement layer of one unitwith a side of an adjacent unit in curtitious shingles, comprisingforming sheet fibrous ing, and curing the units as thus arranged, saidunits being adapted for packaging Without regrouping the individuallayers.

5. The method of making and curing cementitious shingles comprisingapplying a surface layer of plastic hydraulic cement upon fibrous basematerial of suicient rigidity to support by itself said cementsurfacing, said cement surfacing extending over certain edges of saidbase material; forming a compact grouping consisting of a plurality ofunits of said cement surfaced base material, and flexible membranes thatwill not bond to hydraulic cement and of greater dimensions than saidunits, forming said group while the cement is still plastic and formingsaid group with the sides of the units facing each `other` and with saidflexible membranes projecting beyond the edges of the units and coveringthe cementitious surfacings of the units to sube stantially preventbonding of the hydraulic cement side or edge surfacing of one unit withthe side or edges of an adjoining unit in curing, and curing the unitsas thus arranged, said units being adapted for packaging Withoutregrouping the individual layers.

6. The method of making and creating effects on cementitious shingles,comprising securing a surface layer of plastic hydraulic cement to oneside of fibrous base material of sumcient rigidity to support by itselfsaid cement layer, the opposite side of said base material beingsubstantially in dry condition; forming a compact grouping consisting ofa plurality of units of said cement surfaced base material and liquidabsorptive, porous, flexible `membranes that will substantially not bondto hydraulic cement, forming said group while'the cement is stillplastic and forming said group with the moist cement sides of the unitsfacing the dry side of their respective adjacent units and with saidflexible membranes covering the cement surfaced sides and in contactwith the dry side of the adjacent units, and permitting the cementsurfacing to harden while the units are so arranged; said membranessubstantially preventing bonding of the adjacent units in curing andsaid membranes absorbing liquid from said moist cement sides whereby towrinkle and form surface eects upon the cementitious sides and saidunits being adapted for packaging Without regrouping the individuallayers.

' NORMAN P. HARSHZBERGER.

